Today's Technican Automotive Engine Performance

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This comprehensive training and education package focuses on the major engine systems affecting engine performance and driveability, with topics ranging from engine basics to fuel, ignition, and OBD-II systems. Various manufacturers?? vehicle systems are represented to illustrate the similarities and differences technicians will encounter today. Current and thoroughly-updated system information and diagnostic strategies in this edition, added to help students keep pace with emerging technologies, include: ?_ a new systematic approach to diagnosing problems ?_ updated scanner information ?_ new engine technology, including the throttle actuator control system ?_ new magneto resistive sensors ?_ recent emission inspection requirements and mandates specifically regarding OBD II ?_ expanded discussion of fuel cell technology ?_ expanded discussion of the operation of hybrid vehicles Like other books in the Today??s Technician series, the Classroom Manual covers the subject fundamentals, discussing theory and operation of each engine system. The Shop Manual provides the service and diagnostic ??how to?? component, with hands-on exercises that reinforce concepts learned in the Classroom Manual. Restructured Job Sheets in the Shop Manual provide a format for students to perform the tasks covered in each chapter.

Preface

viii

Safety Practices

1

(18)

Introduction

1

(1)

Occupational Safety and Health Act

1

(1)

Shop Hazards

2

(1)

Safety in the Automotive Shop

2

(7)

Shop Safety Equipment

9

(3)

Hazardous Waste Disposal

12

(4)

Summary

16

(1)

Terms to Know

16

(1)

Review Questions

16

(3)

Basic Theories

19

(16)

Introduction

19

(1)

The Basics

19

(1)

Newton's Laws of Motion

20

(1)

Work and Force

20

(1)

Energy

21

(1)

Energy Conversion

21

(2)

Inertia

23

(1)

Momentum

23

(1)

Friction

23

(1)

Mass, Weight, and Volume

23

(1)

Torque

23

(1)

Power

24

(1)

Principles Involving Liquids and Gases

24

(3)

Atmospheric Pressure

27

(1)

Vacuum

28

(1)

Venturi Principle

29

(1)

Combustion

29

(2)

Summary

31

(1)

Terms to Know

31

(1)

Review Questions

32

(3)

Engine Design and Operation

35

(48)

Introduction

35

(1)

Engine Classifications

35

(1)

Engine Location

36

(1)

Characteristics of Four-Stroke Engine Design

36

(2)

Four-Stroke Gasoline Engines

38

(5)

Valve and Camshaft Placement Configurations

43

(1)

Valve and Camshaft Operation

43

(5)

Gasoline Engine Systems

48

(1)

Engine Measurement and Performance

49

(2)

Engine Efficiency

51

(1)

Torque and Horsepower

52

(1)

Other Engine Designs

53

(5)

Engine Lubrication

58

(4)

Lubricating Systems

62

(5)

Cooling Systems

67

(12)

Summary

79

(1)

Terms to Know

79

(2)

Review Questions

81

(2)

Electricity and Electronics

83

(36)

Introduction

83

(1)

Basic Electricity

84

(4)

Types of Circuits

88

(4)

Electromagnetism Basics

92

(3)

Basics of Electronics

95

(4)

Battery, Starting, and Charging Systems

99

(1)

Battery Construction

100

(2)

Battery Operation

102

(2)

Battery Classifications

104

(1)

Battery Ratings

104

(1)

Starting the Engine

104

(6)

AC Generators

110

(5)

Summary

115

(1)

Terms to Know

115

(2)

Review Questions

117

(2)

Ignition Systems

119

(30)

Introduction

119

(1)

Purpose of the Ignition System

120

(1)

Ignition Timing

121

(2)

Basic Ignition System

123

(3)

Ignition Coil Action

126

(3)

Spark Plugs

129

(2)

Spark Timing Systems

131

(1)

Electronic Switching Systems

132

(7)

Timing Advance

139

(3)

Spark Distribution

142

(1)

Computer-Controlled Ignition System Operation

142

(2)

Summary

144

(1)

Terms to Know

144

(1)

Review Questions

145

(4)

Distributor and Electronic Ignition (DI and EI) Systems

149

(52)

Introduction

149

(1)

Distributor Ignition System Components

150

(8)

DI Systems with an External Ignition Module

158

(7)

DI Systems with Computer-Controlled Ignition Timing

165

(1)

Distributors with Optical-Type Pickups

166

(2)

Electronic Ignition (EI) Systems

168

(3)

Basic Components

171

(2)

EI System Operation

173

(2)

EI Systems with the Cam Sensor in the Distributor Opening

175

(3)

EI Systems with the Cam Sensor in the Timing Chain Cover

178

(1)

EI Systems with a Dual Crankshaft Sensor

179

(2)

Fast-Start EI Systems

181

(2)

Fast-Start EI Systems with Two Crankshaft Sensors

183

(4)

EI Systems with a Crankshaft Reluctor Ring

187

(5)

EI Systems with Coils Connected Directly to Spark Plugs

192

(1)

Dual Spark Plug EI Systems

193

(4)

Summary

197

(1)

Terms to Know

197

(1)

Review Questions

197

(4)

Intake and Exhaust Systems

201

(40)

Introduction

201

(1)

Importance of Intake and Exhaust Systems

202

(1)

Air Cleaners

202

(5)

Intake Manifolds

207

(7)

Exhaust System Components

214

(10)

Forced Induction

224

(1)

Turbochargers

224

(4)

Superchargers

228

(6)

Intercoolers

234

(1)

Summary

235

(1)

Terms to Know

235

(2)

Review Questions

237

(4)

Fuel Systems

241

(52)

Introduction

241

(1)

Gasoline Composition

242

(1)

Gasoline Qualities

243

(3)

Basic Fuel Additives

246

(2)

Alternative Fuels

248

(4)

Basic Carburetor Design

252

(3)

Basic Carburetor Circuits

255

(2)

Carburetor Systems

257

(2)

Types of Carburetors

259

(3)

Fuel Injection

262

(1)

Types of Fuel Injection

263

(10)

Fuel Delivery System

273

(16)

Summary

289

(1)

Terms to Know

289

(1)

Review Questions

290

(3)

Computer-Controlled Carburetors

293

(14)

Introduction

293

(2)

Exhaust Gas Oxygen Sensor

295

(1)

Mixture Control Solenoids

296

(2)

Adjustable Mixture Control Solenoid Systems

298

(2)

Electronic Idle Speed Control

300

(3)

Summary

303

(1)

Terms to Know

303

(1)

Review Questions

304

(3)

Electronic Fuel Injection Systems

307

(48)

Introduction

307

(2)

Input Sensors

309

(5)

Basic EFI

314

(4)

Throttle Body Fuel Injection

318

(8)

Port Fuel Injection

326

(9)

Sequential Fuel Injection Systems

335

(11)

Idle Speed Control Systems

346

(5)

Summary

351

(1)

Terms to Know

351

(1)

Review Questions

352

(3)

Emission Control Systems

355

(44)

Introduction

355

(1)

Legislative History

355

(3)

Development of Emission Control Devices

358

(1)

Pollutants

359

(5)

Evaporative Emission Control Systems

364

(3)

Pre-combustion Systems

367

(1)

Engine Design Changes

368

(3)

PCV Systems

371

(2)

Spark Control Systems

373

(2)

EGR Systems

375

(9)

Intake Heat Control Systems

384

(4)

Post-Combustion Systems

388

(1)

Catalytic Converters

388

(1)

Air Injection Systems

389

(6)

Summary

395

(1)

Terms to Know

395

(1)

Review Questions

396

(3)

Computers, Input Sensors, and Actuators

399

(36)

Introduction

399

(2)

Computer Operation

401

(1)

Sensors

401

(6)

Voltage Signals

407

(2)

Input Conditioning

409

(2)

Microprocessors

411

(2)

Types of Computer Memories

413

(2)

Adaptive Strategy

415

(1)

Actuators

416

(2)

Input Sensors

418

(13)

Summary

431

(1)

Terms to Know

431

(2)

Review Questions

433

(2)

On-Board Diagnostic (OBD) II Systems

435

(32)

Introduction

435

(1)

OBD II Introduction and Implementation

436

(2)

Monitoring Capabilities

438

(10)

System Readiness Mode

448

(1)

OBD II Trip

448

(1)

Drive Cycle

449

(1)

Ford's Electronic Engine Control V (EEC V) System

450

(2)

Test Connector

452

(1)

Malfunction Indicator Lamp Operation

453

(1)

Data Links

454

(2)

Test Modes

456

(1)

Snapshots

457

(1)

OBD Terms

457

(6)

Summary

463

(1)

Terms to Know

463

(1)

Review Questions

464

(3)

Related Systems

467

(38)

Introduction

467

(1)

Clutches

468

(4)

Manual Transmissions

472

(2)

Torque Converters

474

(3)

Automatic Transmissions

477

(5)

Driveline

482

(2)

Heating and Air Conditioning

484

(2)

Speed Control Systems

486

(3)

Brake Systems

489

(2)

Suspension and Steering Systems

491

(5)

Wheels and Tires

496

(4)

Summary

500

(1)

Terms to Know

500

(2)

Review Questions

502

(3)

Glossary

505

(24)

Index

529

(140)

Photo Sequence Contents

viii

Job Sheets Contents

ix

Preface

xi

Tools and Safety

1

(24)

Personal Safety

1

(2)

Lifting and Carrying

3

(1)

Hand Tools and Diagnostic Equipment

4

(1)

Hand Tool Safety

5

(1)

Power Tool Safety

6

(1)

Compressed Air Equipment Safety

7

(1)

Lift Safety

8

(2)

Jack and Jack Stand Safety

10

(1)

Cleaning Equipment Safety

11

(2)

Vehicle Operation

13

(1)

Work Area Safety

14

(1)

Employer and Employee Obligations

15

(2)

National Institute for Automotive Service Excellence Certification

17

(3)

Terms to Know

20

(1)

ASE-Style Review Questions

20

(1)

Job Sheets

21

(4)

Typical Shop Procedures and Equipment

25

(48)

Units of Measure

29

(2)

Engine Diagnostic Tools

31

(6)

Electrical Diagnostic Tools

37

(5)

Ignition System Tools

42

(4)

Fuel System Tools

46

(3)

Scan Tools

49

(3)

Oscilloscopes

52

(2)

Exhaust Analyzers

54

(1)

Engine Analyzer

55

(1)

Service Information

56

(9)

Engine Tune-up

65

(1)

Case Study

66

(1)

Terms to Know

67

(1)

ASE-Style Review Questions

67

(2)

Job Sheets

69

(4)

General Engine Condition Diagnosis

73

(44)

General Diagnostic Procedure

73

(1)

Engine Leak Diagnosis

74

(3)

Engine Noise Diagnosis

77

(3)

Engine Exhaust Diagnosis

80

(1)

Diagnosis of Oil Consumption

81

(1)

Engine Oil Pressure Tests

82

(2)

Engine Temperature Tests

84

(1)

Cooling System Inspection and Diagnosis

85

(6)

Vacuum Tests

91

(1)

Exhaust Gas Analyzer

92

(5)

Engine Power Balance Test

97

(2)

Compression Tests

99

(4)

Cylinder Leakage Test

103

(2)

Valve Timing Checks

105

(1)

Valve Adjustment

106

(2)

Case Study

108

(1)

Terms to Know

109

(1)

ASE-Style Review Questions

109

(1)

ASE Challenge Questions

110

(1)

Job Sheets

111

(6)

Basic Electrical Tests and Service

117

(58)

Basic Electrical Diagnosis

117

(4)

Electrical Test Equipment

121

(4)

Digital Multimeter (DMM) Usage

125

(3)

Lab Scope Usage

128

(6)

Logic Probes

134

(1)

Basic Electrical Troubleshooting

134

(2)

Basic Electrical Repairs

136

(3)

Testing Basic Electrical Components

139

(7)

Battery Diagnosis and Service

146

(5)

Charging a Battery

151

(4)

Starter Diagnosis and Service

155

(3)

AC Generator Diagnosis and Service

158

(4)

Case Study

162

(2)

Terms to Know

164

(1)

ASE-Style Review Questions

164

(1)

ASE Challenge Questions

165

(2)

Job Sheets

167

(8)

Ignition System Service and Diagnosis

175

(66)

Introduction

175

(1)

General Ignition System Diagnosis

176

(3)

Visual Inspection

179

(6)

Diagnosing with an Engine Analyzer

185

(5)

Oscilloscope Testing

190

(18)

Individual Component Testing

208

(15)

Setting Ignition Timing

223

(4)

Case Study

227

(1)

Terms to Know

227

(1)

ASE-Style Review Questions

227

(2)

ASE Challenge Questions

229

(2)

Job Sheets

231

(10)

Distributor and Electronic Ignition Systems (DI and EI) Diagnosis and Service